Expandable carton



May 17, 1966 M. HECHTMAN ETAL 3,251,532

EXPANDABLE CARTON 5 Sheets-Sheet 1 Filed May 17, 1965 INVENTORS MARTN HECHTMN ETHEL HERBST fwd ATTORNEYS May 17, 1966 M.' Hr-:cHTMAN ETAL EXPANDABLE CARTON 5 Sheets-Sheet 2 Filed May 17, 1965 INVENTORS MAR 77N HE C H TMAN ETHEL HERBST May 17, 1966 M. HECHTMAN ETAL 3,251,532

EXPANDABLE cARToN Filed May 17. 1965 5 Sheets-Sheet 5 E THE L HERES T A T TOR/VE YS United States Patent Ot 3,251,532 Patented May 17, 1966 3,251,532 EXPANDABLE CARTON Martin Hechtman and Ethel Herbst, New York, NX., assigner-s of one-fourth to Joseph Mandell, New York,

Filed May 17, 1965, Ser. No. 456,068 7 Claims. (Cl. 229-33) This invention relates to improvements in cartons, particularly of the collapsible type, and in particular relates to an improved expandable collapsible carton.

In a number of tields, there :has existed a need for a collapsible carton for shipping purposes or the like, which could be expanded or contracted so as to cover more than one size range, By Way of example, and without limitation thereto, at the present time there are numerous retail businesses, such as bakeries, which must stock Va plurality of cartons, especially paperboard cartons, for packing products which are sold. Thus, a bakery may have cartons 'of different sizes depending upon the quantity and volurne of the order which is to be packed. The need for such' varying size ranges of cartons has required businesses to maintain a large inventory of cartons of vario-11s sizes, which has added to costs and to storage problems.

In view of the foregoing, there lhas existed a need for a carton, which, by way of example, might have -a basic contracted size and which might be expandable, for example, to an intermediate expanded size and to a fully expanded size, so that one carton size could take the place of three of the presently used carton sizes. It is further important that such cartons meet a number of requirements. The carton must be collapsible for shipping and storage purposes, and must be readily expandable to one or more larger sizes, preferably expandable when in erected condition. The carton should be expandable by a simple manual manipulation without the need for cutting or scoring the carton. It is further important that the carton must be provided with positivemeans to maintain it in its contracted or either of its expanded sizes. Furthermore, it should be possible to produce the carton from standard paperboard, on conventional automatic machinery.

An important object of the invention, accordingly, is to provide a carton, and the blank therefor, which meet the foregoing requirements.

Another important object of the invention is to provide a carton of the improved type which can be expanded from a contracted condition to any intermediate condition of increased size and, if desired, to a further condition of maximum size.

In accordance with a preferred embodiment of the invention, there is provided a blank of paperboard or the like for -an expandable and collapsible carton. This blank has a longitudinal axis and `a plurality of longitudinally aligned wall-forming panels, successive panels being hingedly connected to each other along common end edges. Thus, such panels will include at a minimumend panels and a connecting bottom wall panel, and may additionally include cover panel members connected to one of the end wall panels. The blank includes additional wall-forming panels hingedly connected to side edges of the first mentioned panels, which may include as a minimum side wall panels for the bottom receptacle portion of the carton. The panels are positioned and dimensioned and provided with cooperating means permitting assembly of the panels into a collapsible carton which is adapted to be erected with successive first mentioned panels angularly disposed relative to each other., For example, the carton may be one which can be erected to provide a bottom wall and perpendicular side and end walls, together optionally with cover elements connected to one of the end wall panels.

The blank is further provided with at least one pair of of longitudinal, parallel full length fold lines to define aligned fold ap panels in the respective rst mentioned panels between the fold lines. Thus, as a minimum, the fold lines may extend longitudinally across the bottom wall panel and the two connected end wall panels. Optionally, in order to provide for the preferred three sizes of carton, there may be two such pairs of fold lines, each said pair being located adjacent a respective side of the carton.

In setting up the carton, the first mentioned panels (such as the end wall panels and bottom wall panels) may be folded upon the fold lines to overlay the fold tlat panels upon the first mentioned panels so as to establish a contracted condition of the subsequently assembled car-ton. Additionally, customary connections may be completed between, by way of example, the side wall panels and the end wall panels, to form the collapsed assembled carton which is capable subsequently of being erected.

Since it is desired to assemble the carton before expanding it, and to make it possible to expand the carton after it has been erected, it is necessary to provide means permitting unfolding of flaps which will then be disposed in angular relation to each other, such as at right angles. In order to permit this, cutouts are provided in the aps adjacent each common connecting edge of successive longitudinal panels, these cutouts extending the full width between the fold lines and also extending to and interrupting such connecting edge between such fold lines. The provision of such c-utouts facilitates provision of means to lock the carton in expanded condition. In forming the cutouts, oppositely oriented t-abs may be struck from the carton blank, these tabs being respectively connected to the blank along opposite fold lines. However, the connections of the tabs to the blank interrupt the fold lines so that the tabs do not bend when the carton is folded along the fold lines. As a result, when the carton is snapped to extended position, the tabs tend to extend through the cutouts and engage, so as to maintain the carton in extended position.

' An important advantage of the invention resides in the simplicity of use under trying conditions, such as condi tions of sale in retail stores. the carton just like any other carton thereby achieving the carton of minimum volume. If the intermediate size carton is desired, the operator need merely extend one side of the carton, opening up the fold and locking the carton in extended condition. If the full size carton is required, the other side may be similarly extended and locked, or alternatively the two sides may be grasped and pulled apart in one operation so as to open up the carton to maximum volume.

Other objects and advantages of the invention will become apparent from the following description, in conjunction with the annexed drawing, in which a preferred embodiment of the invention is disclosed.

In the drawing,

FIG. l is a top plan view of a preferred carton blank in accordance with this invention, two locking tabs being shown slightly bent out of the plane of the blank solely 4to illustrate the construction more clearly.

FIG. 2 is a perspective view, partly broken away, of the carton in assembled but collapsed condition for shipping or storage,

FIG. 3 is a perspective view of the assembled and open carton in erected and contracted condition,

FIG. 4 is a view similar to FIG. 3, but showing the carton fully extended, this view being partly broken away and certain of the tabs being shown bent out of normal position for illustrative purposes,

. FIG. 5 is a perspective view, partly broken away, of the assembled and closed carton in contracted condition,

In use, the operator erectsv broken away, on lines-8 of FIG. 3,

FIG. 9 is a fragmentary section, partly broken away,

on line 9 9 of FIG. 7.

The drawing is substantially to scale of a working embodiment of the invention, and reference is made to the drawing to complete the disclosure herein.

The blank (FIG. 1)

The carton is formed from a blank 10 shown in FIG. l. This blank 1@ is preferably made of paperboard, but may be made of other suitable material having like characteristics. Blank 11i comprises a bottom Wall panel 11, which may be rectangular and which has end edges 11a and side longitudinal edges 11b. End panels 12 and 13 which are coextensive in width with panel 11 are hingedly connected to such panel 11 along edges 11a. Side wall panels 14, which are coextensive in length with panel 11, are hingedly connected thereto along edges 11b. Panels 12, 13 and 14 are preferably rectangular in shape. Triangular flaps are respectively hingedly connected to the respective side edges 12a and 13a of the respective panels 12 and 13. Each flap 15 is in the form of a right triangle having one edge coextensive with edge 12a or 13a, as the case may be, another short edge aligned with the end edge 12b or 13b of panel 12 or 13 as the case may be, and a di-A agonal hypotenuse edge. Each panel 141 has triangular glued ap portions 16 oriented for registration with respective aps 15 when the walls 12, 13 and 1d are brought into perpendicularity with wall 11 with flaps 15 against the walls 14. The hypotenuse of each flap portion 16 is a fold :line 16a. It will be understood that any suitable conventional corner construction for the receptacle to be formed by the panels 11, 12, 13 and 14, may be employed.

While it is within the scope `of the invention to omit a cover, nevertheless, if a cover is used, it is found advantageous to make the cover integral with the receptacle. Accordingly, in the embodiment shown, cover panel 17 is of the same dimensions as bottom panel 11 and is hingedly connected to panel 13 along edge 13b. Optionally, side flaps 13 are hingedly connected to the side edges of panel 17, and a closure flap 19 is hingedly connected to the end edge 17a of panel 17. Also optionally, panel 19 has a central end extension 2G corresponding in lateral position and width to a slot 21 formed in the hinge line 11a.

The panels 12, 11, 13, 17 and 19 may be considered to be a plurality of longitudinally aligned wallforming panels having end edges with successive panels being hingedly connected vto each other along common end edges. The panels 14 and 18 may be considered to be additional wall-forming panels hingedly connected to side edges `of the first mentioned panels 12, 11, 13, 17 and 19. The panels 12, 13, and 14 may be considered as positioned and dimensioned and having cooperating means 15, 16 permitting assembly of said panels into a collapsible carton which is adapted to be erected with successive first-mentioned panels 12, 11, 13, 17 and 19, angularly disposed relative to each other.

Adjacent each side of the first-mentioned wall-forming panels 12, 11, 13, 17 and 19, blank 10 has a pair of longitudinal, parallel full length fold lines 22 to define aligned fold panels between the lines 22; namely, fold panel 32 in panel 12, 31 in panel 11, 33 in panel 13, 37 in panel Y 17, and 39 in panel 19. Panels 32, 31, 33, 37 Iand 39 are vfoldable upon the inner fold line 22 to overlie and abut the respective panels 12, 11, 13, 17 and 19. The panels 12, 11, 13, 17 and 19 are foldable upon the outer fold line 22 to overlie the respective panels 32, 31, 33, 37 and 39. The manner in which such folds can be formed is clearly shown in the various views, of which FIGS. 2, 5

and 8 may be considered to be illustrative with respect to this feature. It will be understood that the fold lines 22 can be scored in the usual manner to facilitate the abovedescribed folds and thereby to tend to bias the blank towards the tension of such folds once formed.-

The lateral location and spacing of the fold lines 22 will depend upon the various possible carton dimensions which are desired.' Preferably, as shown, the fold llines 22 are located somewhat closer to the side edges 11b than to the center' longitudinal line of panel 11. The spacing between the lines 22 is selected so as to make it possible to produce three relatively standard sizes of cartons as used, for example, in the retail bakery business.

As a further feature of the invention, a pair of tabs 23 are struck from carton blank 10 between the fold lines 22, in association with each of the edge lines 11a, 13b, and 17a. Put in other terms, tabs 23 and 24 are struck from the respective flaps 32, 31, 33, 37 and 39 adjacent each common connecting edge of successive flaps. The tabs 23 and 24 of each pair are oppesitely oriented and are connected to the blank 1d along opposite fold lines 22. Thus the tab 24 has a base edge connection with blank 1l) which is aligned with the outer fold line 22. The tab 23 has a base edge connection with blank 1G in alignment with the inner fold line 22. Such base connections of tabs 24 and 23 are unscored and define interruptions 24a and 23a, respectively, in the fold lines 22 so that when the above-described folding operation takes place, the tabs 23 and 24 are not folded. The tabs 23 and 24 are otherwise completely cut from blank 1@ to define respective cutouts 26 and 27. The two cutouts 25 and 27 meet across the respective connection lines 17a, 13b, 11a so as to define a cutout extending in each instance across the common edge. In addition, the tabs define a common cutout 26, 27 extending the full distance between the fold lines 22. The remote edges of the cutouts 26 and 27 are arcuate corresponding to the convex edges of the tabs 23 and 24, as clearly shown in FIG. 1 and other views.

The assembled, collapsed carton (FIG. 2)

In the assembly of the carton, the panels 39, 3'7, 33, 31 and 32 are folded on the inner fold line 22 to overlie the respective panels 19, 17, 13, 11a and 12, and the last mentioned panels are folded upon the outer fold lines 22 to overlie the fold panels 39, 37, 33, 31 and 32, as described above. The tabs 24 are then located wholly inwardly of the two score lines 22, and the tabs 23 are then located completely outwardly of the two fold lines 22. It will be understood that this process is completed for both sides. The panels are then folded, in usual known manner,

which need not be described in detail, to bring flaps 15 l in registration with the'flaps 16, to which they are glued in the usual manner, and the flaps 16 are further folded back upon themselves against the main portions of panels 14 to achieve the usual collapsed position of the receptacle portion of the carton. The cover panels 18 and 19 are folded over upon panel 17 for collapsing of the cover portion of the carton in usual manner, and the cover panel 17 is folded over into parallelism with panel 11 to complete the formation of the collapsed assembled carton. The carton is thereby assembled and collapsed in its most compact form, and may readily be shipped or stored.

The erection of the Carton The carton is first erected in contracted condition, as shown in FIGS. 3, 5, 7, 8 and 9.

Such erection of carton can be done entirely conventionally without the need for any special instruction of the operator. The cover panel 17 is raised to perpendicube -bent outwardly, thereby achieving the intermediate condition of FIG. 3. If it is desired to fill the carton in its contracted condition of FIG. 3, the cover 17 is simply closed with the panels 18 optionally inside the side wall panels 14, and with panel 19 inside and against panel 12 with tab 20 extended through slot 21 (see FIG. 5).

Reference is made to FIG. 7 to show that the tabs 23 connected to the bottom panel 11 extend to the outer sides of the carton, but not beyond such outer sides. FIG. 7 also shows how the tabs 24 connected to the front wall panel 12 extend inwardly of the folds.

` It should be understood that even if the fold lines 22 are not formed so as to have a biasing effect, the carton will still tend to retain its contracted condition. Thus, when the carton is closed, the cover flaps 18 and 19 rest upon folds and tend to prevent them from opening up. Similarly, the cover folds are inhibited from expanding by reason of the location of one or more of the cover flaps within the receptacle portion of the carton.

Expansion of the carton The carton will ordinarily be expanded while in its open position of FIG. 3. FIGS. 4 and 6 show the carton fully expanded, but it will be apparent that if desired, only one of the sides may be expanded. Expansion of either or both sides of the carton may be accomplished simply by pulling the side of the carton outwardly with respect to the center portion of the carton, and this operation may be readily performed by personnel withoutthe need for training. Such expansion of thecarton can be obtained, despite the perpendicular relationship of successive folded portions of the carton, because of the provision of the cutouts 26 and 27, coupled with the resiliency of the paperboard stock. Thus, the cutouts are dimensioned, shaped and located to permit the ycarton movement between its contracted and expanded conditions. The effect of the outward movement of the side portion of the carton is to reverse the folded condition shown in FIGS. 2 and 3 and other views, and to return the panels, 12, 11, 13, 17 and 19 to respective planar conditions of FIG. 1.

y The further result is to restore the respective tabs 23 and 24 into registration with their associated cutouts 26 and 27. If tabs 23 and 24 at right angles to each other are considered, the straight free edge of one tab then tends to abut the fact the adjacentA and associated tab, or vice versa, so that the two associated tabs 23 and 24 serve as a lock to retain the carton in expanded condition. Therefore, the resi-liency of the carton along the fold lines 22 is met by engagement of the various pairs of tabs 23 and 24, so as to assure a stable expanded condition of the carton. It will be understood that it is not necessary that each interlock succeed, or in other Words it is not serious if one or more pairs of tabs fail to engagebecause once the carton is filled and the cover closed, the location of the cover panels within the walls of the receptacle portion of the carton will increase the stability and substantially prevent contractionof the carton. But in other terms, it would be extremely difficult to contract the closed and expanded carton of FIG. 6 to the contracted carton of FIG. 5. Parenthetieally, it may be stated that it would be extremely difiicult to expand the carton of FIG. 5 to the condition of FIG. 6.

From thev foregoing, it will be readily apparent that the carton in accordance with this invention can have a contracted condition, an intermediate expanded condition, and a maximum expanded condition, corresponding to three sizes of conventional cartons, so that for such three sizes it is now only necessary to stock one size of carton. This results in economies in inventory and in economies in storage space. Furthermore, the carton can be produced on standard carton making equipment from standard paperboard. Additionally, the carton may be completely assembled prior to handling in the final filling operation. Furthermore, the operator can erect the carand atuek flap hingedly connected to the lateral edgel ton in accordance-with conventional, simple procedure, to achieve the contracted carton ready for filling. Finally, if the carton is to be enlarged, the operator, prior to filling and closing the cover, can simply exert an outward force on one or both sides of the carton to snap the carton to enlarged size, without the need for difficult handling or cutting or gluing operations.

While a preferred embodiment of the invention has been disclosed, and various possible changes, omissions and additions have been indicated therein, it will be apparent that various other changes, omissions and additions may be made in the invention Without departing from the scope and spirit thereof.

What is claimed is:

1. Expansible carton of paperboard and the like comprising a bottom wall having end edges and side longitudinal edges, end and side walls respectively hingedly connected to said end and side edges and to each other, said carton being maintainable in erected condition with said end and side walls upstanding relative to said bottom wall, said carton having a pair of parallel fold lines extending in said bottom wall between said end edges and continuing in said end walls to the upper edges thereof to define fold panels in said bottom and end walls between said fold lines, said bottom and end walls being foldable upon said fold lines to overlay said fold panels thereupon to establish a contracted condition of said carton and to move said fold panels into co-planarity with said bottom and end walls to establish an expanded condition of said carton, saidl carton having cutouts between said fold lines and across each end edge of said bottom wall and dimensioned, shaped and located to permit carton movement between its contracted and expanded conditions.

2. Expansible carton of paperboard and the like comprising a bottom wall having end edges and side longitudinal edges, end and side Walls respectively hingedly connected to said end and side edges and to each other in such a way as to permit establishment of a collapsed condition of said carton in which said end and side walls overlay said bottom wall, said carton having a pair of parallel fold lines extending in said bottom wall between said end edges and continuing in said end walls to the upper edges thereof to define fold panels in said bottom and end walls between said fold lines, the respective adjacent bottom and end fold panels having tabs struck therefrom and oppositely oriented with said tabs connected to said carton along opposite fold linessaid tabs defining a cutout extending across the common edge of said end wall and said bottom wall and-extending the full distance between said fold lines, said tabs interrupting said fold lines, said bottom and end walls being folded upon said fold lines to overlay said flaps upon said bottom and end walls but with said tabs remaining unfolded, the connections of the side and end walls to each other being such as to permit movement of the carton from its collapsed condition to erected condition in which said side and end walls are upstanding relative to said bottom wall, said carton being adapted then to be expanded by exerting force outwardly on the sides thereof so as to unfold the fold aps, the adjacent tabs of said bottom wall and each end Wall being than shaped and adapted to move through said cutouts for engagement one against the other to lock the carton in its expanded condition.

3. Expansible carton of paperboard and the like comprising a rectangular bottom wall having end edges and side longitudinal edges, rectangular end and side walls respectively hingedly connected to said end and side edges and to each other in such a way as to per-mit establishment of a collapsed condition of said carton in which said end and side Walls overlie said bottom wall, a rectangular cover wall hingedly connected to the upper edge of one of said end walls and sized and adapted to be folded into overlying parallel relationship with said bottom wall,

of said cover Wall remote from the end wall to which it is connected and adapted to be tucked inside4 the other end wall to close the cover, said carton having a pair of inner and outer parallel fold lines extending in said bottom wall between said end edges, continuing in said end walls to the upper edges thereof, and further continuing in said cover between the lateral edges thereof and in said tuck flap between its lateral edges t-o define fold panels in the respective walls between said fold lines, respective successive fold panels having tabs struck therefrom and oppositely oriented with said tabs connected to said cartons along opposite fold lines, said tabs defining a cutout extending across the common edge of said successive fold panels and extending the full distance between said fold lines, said tabs interrupting said fold lines, the carton walls being folded upon said fold lines to overlay said fold panels upon their associated walls and to further overlay the associated walls upon said fold panels to define a collapsed condition of said carton, said carton being adapted to be expanded by exerting force outwardly on the sides thereof so as to unfold the fold flaps, the respective pairs of advjacent tabs being then shaped and adapted to move through said cutouts for engagement one against the other `to lock the carton in its expanded condition.

4. Expansible carton of paperboard and the like comprising a bottom wall having end edges and side longitudinal edges, and end and side walls respectively connected to said end and side edges and to each other, said carton having a pair of parallel fold lines extending in said bottom wall between said end edges and continuing in said end walls to the upper edges thereof to define fold panels in said bottom and end walls between said fold lines, said bottom and end walls being foldable upon said fold lines to overlay said 'fold panels thereupon to establish a contracted condition of said carton and to move said fold panels into co-planarity with said botto-m and end walls to establish an expanded condition of said carton, said carton lhaving cutouts extending to said end edges and to said fold lines and sized, shaped and positioned to permit the folding and unfolding of said bottom 4and end walls on said .fold lines.

5. VCarton according to claim 4, said carton having tabs struck therefrom in said fold panels and extending to each end edge and positioned and adapted to lock said car-ton in expanded condition when moved thereto from contracted condition.

6. Blank of paperboard and the like for expansible carton comprising a bottom wall panel having end edges and side longitudinal edges, end and side wall panels respectively hingedly connected to said end and side edges and having means connectable to each other for assembling the carton with said walls bendable rela-tive to each `other to overlay said side and end walls upon said bottom wall to establish a attened and collapsed condition of said carton and rto position said side and end walls upstanding relative to said bottom wall to establish an erected condition of said carton, said blank having a pair of longitudinal, parallel full-length fold lines to define aligned fold panels between said fold lines respectively in said bottom wall panel and said end wall panels, said blank being foldable upon said fold lines to overlay said fold fiap panels upon said bottom `and end wall panels to establish a contracted condition of the carton when subsequently assembled, said blank having cutouts extending between said fold lines and across each end edge of said bottom wall panel and dimensioned, shaped and located so as to permit expansion of the setup and erected carton by unfolding its Ibottom and end panels on said fold lines.

7. Blank of paperboard and the like for expansible carton, said blank having a longitudinal axis, said blank comprising a plurality of longitudinally aligned wallforming panels having end edges and side edges, successive panels being hingedly connected lto each other along common end edges, additional wall-forming panels hingedly connected to side edges of said first-mentioned panels, said panels positioned and dimensioned and having cooperating means permitting assembly of said panels into a collapsible carton which is adapted to be erected with successive first-mentioned panels angularly disposed relative to each other, said blank having a pair of longitudinal, parallel full-length fold lines to define aligned fold panels in the respective first-mentioned panels between said fold lines, said first-mentioned panels being foldable upon said fold lines to overlay said fold panels upon said first-mentioned panels to establish a contracted condition of the carton when subsequently assembled, said fold panels adjacent each common connecting edge thereof having tabs struck therefrom and oppositely oriented with said tabs connected to said carton along opp-osite fold lines, said tabs defining a cutout extending across the common edge and extending the full distance between the fold lines, said tabs interrupting said fold lines. v

References Cited by the Examiner UNITED STATES PATENTS 2,077,694 4/ 1937 Hinton 229-33 3,198,420 8/1965 Hiersteiver 229-6 X FOREIGN PATENTS 458,893 8/1950 Italy. 614,223 12/1948 Great Britain.

JOSEPH R. LECLAIR, Primary Examiner.`

R. PESHOCK, Assl'stanl Examiner. 

1. EXPANSIBLE CARTON OF PAPERBOARD AND THE LIKE COMPRISING A BOTTOM WALL HAVING END EDGES AND SIDE LONGITUDINAL EDGES, END AND SIDE WALLS RESPECTIVELY HINGEDLY CONNECTED TO SAID END AND SIDE EDGES AND TO EACH OTHER, SAID CARTON BEING MAINTAINABLE IN ERECTED CONDITION WITH SAID END AND SIDE WALLS UPSTANDING RELATIVE TO SAID BOTTOM WALL SAID CARTON HAVING A PAIR OF PARALLEL FOLD LINES EXTENDING IN SAID BOTTOM WALL BETWEEN SAID END EDGES AND CONTINUING IN SAID END WALLS TO THE UPPER EDGES THEREOF TO DEFINE FOLD PANELS IN SAID BOTTOM AND END WALLS BETWEEN SAID FOLD LINES, SAID BOTTOM AND END WALLS BEING FOLDABLE UPON SAID FOLD LINES TO OVERLAY SAID FOLD PANELS THEREUPON TO ESTABLISH A CONTRACTED CONDITION OF SAID CARTON AND TO MOVE SAID FOLD PANELS INTO CO-PLANARITY WITH SAID BOTTOM AND END WALLS TO ESTABLISH AN EXPANDED CONDITION OF SAID CARTON, SAID CARTON HAVING CUTOUTS BETWEEN SAID FOLD LINES AND ACROSS EACH END EDGE OF SAID BOTTOM WALL AND DIMENSIONED, SHAPED AND LOCATED TO PERMIT CARTON MOVEMENT BETWEEN ITS CONTRACTED AND EXPANDED CONDITIONS. 